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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 May 2022) | Viewed by 40072

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Dr. Radu Robert Piticescu

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National Research and Development Institute for Nonferrous and Rare Metals-IMNR, 102 Biruntei Blvd, Pantelimon, Ilfov, Romania
Interests: advanced nanostructured materials; hydrothermal synthesis; functional graded materials; coatings technologies
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Dear Colleagues,

Development of new material systems and coatings is a multidisciplinary topic of high importance for scientists and technologists, providing remarkable functional properties improving performances in many traditional and high-tech industrial areas. New or emerging technologies for materials synthesis and processing are needed to obtain materials systems and coatings with design composition, microstructure, and architectures fulfilling the harsh requirements for applications in extreme mechanical, high-temperature, high-corrosion or biological–environmental conditions. Green chemical procedures with a low environmental impact enable finetuning of components and dopants by controlling the kinetics and mechanisms involved in the synthesis of nanostructured composite or hybrid material systems. The use of these advanced materials to obtain functionally graded materials and coating architectures may open new directions in the study of nucleation and growth processes while using physical or chemical coating technologies and controlling functional properties. Additionally, additive manufacturing combined with coating technologies may strongly contribute to reducing the use of some critical raw materials.

In this Special Issue, modern trends in novel material synthesis and coatings, including fundamental research, modeling, and optimization, are highlighted and discusses.

It is my pleasure to invite you to submit a manuscript to this Special Issue. Full papers, communications, and reviews are all welcome.

Dr. Radu Robert Piticescu
Guest Editor

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Keywords

Nanomaterials
Green chemistry synthesis
Hydrothermal/solvothermal
Sol–gel
Mechanosynthesis
Coatings
Functionally-graded materials
Additive manufacturing
EB-PVD
RF/magnetron sputtering
Chemical vapor deposition methods
Ab initio modeling and simulation

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Related Special Issue

Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2) in Materials (11 articles)

Published Papers (12 papers)

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Research

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21 pages, 7935 KiB

Open AccessArticle

Hydrothermal Synthesis of Nanocrystalline ZrO₂-8Y₂O₃-xLn₂O₃ Powders (Ln = La, Gd, Nd, Sm): Crystalline Structure, Thermal and Dielectric Properties

by Radu-Robert Piticescu, Anca Elena Slobozeanu, Sorina Nicoleta Valsan, Cristina Florentina Ciobota, Andreea-Nicoleta Ghita, Adrian Mihail Motoc, Stefania Chiriac and Mythili Prakasam

Materials 2021, 14(23), 7432; https://doi.org/10.3390/ma14237432 - 3 Dec 2021

Cited by 5 | Viewed by 2739

Abstract

Zirconium dioxide (ZrO₂) is one of the ceramic materials with high potential in many areas of modern technologies. ZrO₂ doped with 8 wt.% (~4.5 mol%) Y₂O₃ is a commercial powder used for obtaining stabilized zirconia materials (8 wt.% YSZ) with high temperature resistance and good ionic conductivity. During recent years it was reported the co-doping with multiple rare earth elements has a significant influence on the thermal, mechanical and ionic conductivity of zirconia, due complex grain size segregation and enhanced oxygen vacancies mobility. Different methods have been proposed to synthesize these materials. Here, we present the hydrothermal synthesis of 8 wt.% (~4.5 mol%) YSZ co-doped with 4, 6 and 8 wt.% La₂O₃, Nd₂O₃, Sm₂O₃ and Gd₂O₃ respectively. The crystalline phases formed during their thermal treatment in a large temperature range were analyzed by X-ray diffraction. The evolution of phase composition vs. thermal treatment temperatures shows as a major trend the formation at temperatures >1000 °C of a cubic solid solutions enriched in the rare earth oxide used for co-doping as major phase. The first results on the thermal conductivities and impedance measurements on sintered pellets obtained from powders co-doped with 8 wt.% Y and 6% Ln (Ln = La, Nd, Sm and Gd) and the corresponding activation energies are presented and discussed. The lowest thermal conductivity was obtained for La co-doped 8 wt.% YSZ while the lowest activation energy for ionic conduction for Gd co-doped 8 wt.% YSZ materials. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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13 pages, 2262 KiB

Open AccessArticle

Screen Printed Copper and Tantalum Modified Potassium Sodium Niobate Thick Films on Platinized Alumina Substrates

by Brigita Kmet, Danjela Kuščer, Soma Dutta, Hana Uršič, Aleksander Matavž, Franck Levassort, Vid Bobnar, Barbara Malič and Andreja Benčan

Materials 2021, 14(23), 7137; https://doi.org/10.3390/ma14237137 - 24 Nov 2021

Cited by 4 | Viewed by 2290

Abstract

We show how sintering in different atmospheres affects the structural, microstructural, and functional properties of ~30 μm thick films of K_0.5Na_0.5NbO₃ (KNN) modified with 0.38 mol% K_5.4Cu_1.3Ta₁₀O₂₉ and 1 mol% CuO. The films were screen printed on platinized alumina substrates and sintered at 1100 °C in oxygen or in air with or without the packing powder (PP). The films have a preferential crystallographic orientation of the monoclinic perovskite phase in the [100] and [−101] directions. Sintering in the presence of PP contributes to obtaining phase-pure films, which is not the case for the films sintered without any PP notwithstanding the sintering atmosphere. The latter group is characterized by a slightly finer grain size, from 0.1 μm to ~2 μm, and lower porosity, ~6% compared with ~13%. Using piezoresponse force microscopy (PFM) and electron backscatter diffraction (EBSD) analysis of oxygen-sintered films, we found that the perovskite grains are composed of multiple domains which are preferentially oriented. Thick films sintered in oxygen exhibit a piezoelectric d₃₃ coefficient of 64 pm/V and an effective thickness coupling coefficient k_t of 43%, as well as very low mechanical losses of less than 0.5%, making them promising candidates for lead-free piezoelectric energy harvesting applications. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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19 pages, 58615 KiB

Open AccessArticle

Novel Catalytic Ceramic Conversion Treatment of Ti6Al4V for Improved Tribological and Antibacterial Properties for Biomedical Applications

by James Alexander, Huan Dong, Deepa Bose, Ali Abdelhafeez Hassan, Sein Leung Soo, Zhenxue Zhang, Xiao Tao, Sarah Kuehne, Xiaoying Li and Hanshan Dong

Materials 2021, 14(21), 6554; https://doi.org/10.3390/ma14216554 - 1 Nov 2021

Cited by 1 | Viewed by 2355

Abstract

Titanium oxide layers were produced via a novel catalytic ceramic conversion treatment (CCCT, C3T) on Ti-6Al-4V. This CCCT process is carried out by applying thin catalytic films of silver and palladium onto the substrate before an already established traditional ceramic conversion treatment (CCT, C2T) is carried out. The layers were characterised using scanning electron microscopy, X-ray diffraction, transmission electron microscopy; surface micro-hardness and reciprocating tribological performance was assessed; antibacterial performance was also assessed with S. aureus. This CCCT has been shown to increase the oxide thickness from ~5 to ~100 µm, with the production of an aluminium rich layer and agglomerates of silver and palladium oxide surrounded by vanadium oxide at the surface. The wear factor was significantly reduced from ~393 to ~5 m³/N·m, and a significant reduction in the number of colony-forming units per ml of Staphylococcus aureus on the CCCT surfaces was observed. The potential of the novel C3T treatment has been demonstrated by comparing the performance of C3T treated and untreated Ti6Al4V fixation pins through inserting into simulated bone materials. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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18 pages, 5307 KiB

Open AccessArticle

Study of ZnO-CNT Nanocomposites in High-Pressure Conditions

by Laura-Madalina Cursaru, Sorina Nicoleta Valsan, Maria-Eliza Puscasu, Ioan Albert Tudor, Nicoleta Zarnescu-Ivan, Bogdan Stefan Vasile and Roxana Mioara Piticescu

Materials 2021, 14(18), 5330; https://doi.org/10.3390/ma14185330 - 15 Sep 2021

Cited by 23 | Viewed by 3854

Abstract

Recently, carbon nanotubes (CNTs) have been used extensively to develop new materials and devices due to their specific morphology and properties. The reinforcement of different metal oxides such as zinc oxide (ZnO) with CNT develops advanced multifunctional materials with improved properties. Our aim is to obtain ZnO-CNT nanocomposites by in situ hydrothermal method in high-pressure conditions. Various compositions were tested. The structure and morphology of ZnO-CNT nanocomposites were analyzed by Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry—thermogravimetry (DSC-TG), X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and transmission electron microscopy (TEM). These analyses showed the formation of complex ZnO-CNT structures. FT-IR spectra suggest possible interactions between CNT and ZnO. DSC-TG analysis also reveals the formation of some physical bonds between ZnO and CNT, through the appearance of endothermic peaks which could be assigned to the decomposition of functional groups of the CNT chain and breaking of the ZnO-CNT bonds. XRD characterization demonstrated the existence of ZnO nanocrystallites with size around 60 nm. The best ZnO:CNT composition was further selected for preliminary investigations of the potential of these nanocomposite powders to be processed as pastes for extrusion-based 3D printing. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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14 pages, 4800 KiB

Open AccessArticle

Investigation of Post-Processing of Additively Manufactured Nitinol Smart Springs with Plasma-Electrolytic Polishing

by Vincent N. Stepputat, Henning Zeidler, Daniel Safranchik, Evgeny Strokin and Falko Böttger-Hiller

Materials 2021, 14(15), 4093; https://doi.org/10.3390/ma14154093 - 22 Jul 2021

Cited by 22 | Viewed by 2791

Abstract

Additive manufacturing of Nitinol is a promising field, as it can circumvent the challenges associated with its conventional production processes and unlock unique advantages. However, the accompanying surface features such as powder adhesions, spatters, ballings, or oxide discolorations are undesirable in engineering applications and therefore must be removed. Plasma electrolytic polishing (PeP) might prove to be a suitable finishing process for this purpose, but the effects of post-processing on the mechanical and functional material properties of additively manufactured Nitinol are still largely unresearched. This study seeks to address this issue. The changes on and in the part caused by PeP with processing times between 2 and 20 min are investigated using Nitinol compression springs manufactured by Laser Beam Melting. As a benchmark for the scanning electron microscope images, the differential scanning calorimetry (DSC) measurements, and the mechanical load test cycles, conventionally fabricated Nitinol springs of identical geometry with a medical grade polished surface are used. After 5 min of PeP, a glossy surface free of powder adhesion is achieved, which is increasingly levelled by further polishing. The shape memory properties of the material are retained without a shift in the transformation temperatures being detectable. The decreasing spring rate is primarily attributable to a reduction in the effective wire diameter. Consequently, PeP has proven to be an applicable and effective post-processing method for additively manufactured Nitinol. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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20 pages, 5161 KiB

Open AccessFeature PaperArticle

PROMETHEUS: A Copper-Based Polymetallic Catalyst for Automotive Applications. Part II: Catalytic Efficiency an Endurance as Compared with Original Catalysts

by Iakovos Yakoumis, Εkaterini Polyzou and Anastasia Maria Moschovi

Materials 2021, 14(9), 2226; https://doi.org/10.3390/ma14092226 - 26 Apr 2021

Cited by 7 | Viewed by 2419

Abstract

PROMETHEUS catalyst, a copper-based polymetallic nano-catalyst has been proven to be suitable for automotive emission control applications. This novel catalyst consists of copper, palladium and rhodium nanoparticles as active phases, impregnated on an inorganic oxide substrate, CeO₂/ZrO₂ (75%, 25%). The aim of PROMETHEUS catalyst’s development is the substitution of a significant amount (85%) of Platinum Group Metals (PGMs) with copper nanoparticles while, at the same time, presenting high catalytic efficiency with respect to the commercial catalysts. In this work, an extensive investigation of the catalytic activity of full scale PROMETHEUS fresh and aged catalyst deposited on ceramic cordierites is presented and discussed. The catalytic activity was tested on an Synthetic Gas Bench (SGB) towards the oxidation of CO and CH₄ and the reduction of NO. The loading of the washcoat was 2 wt% (metal content) on Cu, Pd, Rh with the corresponding metal ratio at 21:7:1. The concentration of the full-scale monolithic catalysts to be 0.032% total PGM loading for meeting Euro III standard and 0.089% for meeting Euro IV to Euro VIb standards. The catalytic activity of all catalysts was tested both in rich-burn (λ = 0.99) and lean-burn conditions (λ = 1.03). Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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16 pages, 9077 KiB

Open AccessArticle

A Simple Method for a Protective Coating on Stainless Steel against Molten Aluminum Alloy Comprising Polymer-Derived Ceramics, Oxides and Refractory Ceramics

by Sébastien Quenard and Marilyne Roumanie

Materials 2021, 14(6), 1519; https://doi.org/10.3390/ma14061519 - 19 Mar 2021

Cited by 6 | Viewed by 3501

Abstract

A new coating based on polymer-derived ceramics (PDC), oxides and refractory ceramic with a thickness of around 50 µm has been developed to improve the resistance corrosion of stainless steel substrate against molten aluminum alloy in a thermal energy storage (TES) system designed to run at high temperature (up to 600 °C). These coatings implemented by straightforward methods, like tape casting or paintbrush, were coated on planar and cylindrical stainless-steel substrates, pyrolyzed at 700 °C before being plunged for 600 and 1200 h in molten AlSi₁₂ at 700 °C. The stainless-steel substrate appears healthy without intermetallic compounds, characteristic of molten aluminum alloy corrosion. The protective coating against AlSi₁₂ corrosion shows excellent performance and appears interesting for TES applications. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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19 pages, 7464 KiB

Open AccessArticle

PROMETHEUS: A Copper-Based Polymetallic Catalyst for Automotive Applications. Part I: Synthesis and Characterization

by Iakovos Yakoumis

Materials 2021, 14(3), 622; https://doi.org/10.3390/ma14030622 - 29 Jan 2021

Cited by 7 | Viewed by 3500

Abstract

According to the strict European exhaust emissions standards that have been imposed by European legislation there is an elevated need for the decrease of the toxic gas emissions from vehicles. Therefore, car manufacturers have implemented a series of catalytic devices in the aftertreatment of the engine to comply with the standards. All catalytic devices (such as three-way catalysts, diesel particulate filters and diesel oxidation catalysts) accumulate concentrated loading of platinum group metals (PGMs, platinum, palladium, rhodium) as the active catalytic phase. Thus, the demand for PGMs is constantly increasing with a subsequent increase in their market prices. As a result, the research on catalytic converters of high activity and reduced cost/PGM loading is of great interest. In the present work, the Prometheus catalyst, a polymetallic nanosized copper-based catalyst for automotive emission control applications, is presented in two different metal loadings (2 wt% and 5 wt%) and metal ratios (Cu/Pd/Rh = 21/7/1 and Cu/Pd/Rh = 21/7/3). For the first time, a three-metal (copper, palladium, rhodium) nano-catalyst has been synthesized and characterized on a large scale. By using copper as an active catalytic phase, a reduction of PGMs loading is achieved (up to 85%) resulting in a novel catalytic device with similar or improved catalytic performance compared to commercial ones. The Prometheus catalyst is prepared by a wet impregnation method, using as a carrier an inorganic mixed oxide (CeZrO₄) exhibiting elevated oxygen storage capacity (OSC). The heterogeneous catalytic powders produced were characterized by both spectroscopic and analytical methods. The metal content and ratio were determined by inductively coupled plasma mass spectrometry (ICP-MS), X-ray fluorescence (XRF) and energy-dispersive X-ray spectroscopy (EDS). The morphology and the catalyst particle size were determined with scanning electron microscopy (SEM) and X-ray diffraction (XRD). The investigation revealed homogeneous particle formation and dispersion. The deposition of the metal nanoparticles on the porous inorganic carrier was verified with N₂ sorption. Catalytic performance and reactivity of a catalyst (pure wash coat) with molar ratio 21/7/1 and a full-scale Prometheus catalyst with the desired loading of 15 g/ft³ were tested on an in-house synthetic gas bench (SGB) for the abatement of CO, CH₄ and NO, both presenting high catalytic activity. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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12 pages, 3831 KiB

Open AccessArticle

Methane Combustion Using Pd Deposited on CeO_x-MnO_x/La-Al₂O₃ Pellistors

by Ovidiu G. Florea, Adelina Stănoiu, Marin Gheorghe, Cornel Cobianu, Florentina Neaţu, Mihaela M. Trandafir, Ştefan Neaţu, Mihaela Florea and Cristian E. Simion

Materials 2020, 13(21), 4888; https://doi.org/10.3390/ma13214888 - 30 Oct 2020

Cited by 3 | Viewed by 2114

Abstract

Pd deposited on CeO_x-MnO_x/La-Al₂O₃ has been prepared as a sensitive material for methane (CH₄) detection. The effect of different amounts (1.25%, 2.5% and 5%) of Pd loading has been investigated. The as prepared materials were deposited on Pt microcoils using a drop-coating method, as a way of developing pellistors operated using a Wheatstone bridge configuration. By spanning the operating temperature range between 300 °C and 550 °C, we established the linearity region as well as the maximum sensitivity towards 4900 ppm of CH₄. By making use of the sigmoid dependence of the output voltage signal from the Wheatstone bridge, the gas surface reaction and diffusion phenomena have been decoupled. The pellistor with 5% Pd deposited on CeO_x-MnO_x/La-Al₂O₃ exhibited the highest selective-sensitivity in the benefit of CH₄ detection against threshold limits of carbon monoxide (CO), sulfur dioxide (SO₂) and hydrogen sulfide (H₂S). Accordingly, adjusting the percent of Pd makes the preparation strategies of pellistors good candidates towards CH₄ detection. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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24 pages, 6521 KiB

Open AccessArticle

Tensile Notch Sensitivity of Additively Manufactured IN 625 Superalloy

by Gheorghe Matache, Alexandru Paraschiv and Mihaela Raluca Condruz

Materials 2020, 13(21), 4859; https://doi.org/10.3390/ma13214859 - 29 Oct 2020

Cited by 5 | Viewed by 2828

Abstract

The notch sensitivity of additively manufactured IN 625 superalloy produces by laser powder bed fusion (LPBF) has been investigated by tensile testing of cylindrical test pieces. Smooth and V-notched test pieces with four different radii were tested both in as-built state and after a stress relief heat treatment for 1 h at 900 °C. Regardless of the notch root radius, the investigated alloy exhibits notch strength ratios higher than unity in both as-built and in stress-relieved states, showing that the additive manufactured IN 625 alloy is not prone to brittleness induced by the presence of V-notches. Higher values of notch strength ratios were recorded for the as-built material as a result of the higher internal stress level induced by the manufacturing process. Due to the higher triaxiality of stresses induced by notches, for both as-built and stress-relieved states, the proof strength of the notched test pieces is even higher than the tensile strength of the smooth test pieces tested in the same conditions. SEM fractographic analysis revealed a mixed mode of ductile and brittle fracture morphology of the V-notched specimens regardless the notch root radius. A more dominant ductile mode of fracture was encountered for stress-relieved test pieces than in the case of the as-built state. However, future research is needed to better understand the influence of notches on additive manufactured IN 625 alloy behaviour under more complex stresses. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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22 pages, 9242 KiB

Open AccessArticle

Microstructural and Tensile Properties Anisotropy of Selective Laser Melting Manufactured IN 625

by Mihaela Raluca Condruz, Gheorghe Matache, Alexandru Paraschiv, Tiberius Florian Frigioescu and Teodor Badea

Materials 2020, 13(21), 4829; https://doi.org/10.3390/ma13214829 - 28 Oct 2020

Cited by 21 | Viewed by 3076

Abstract

The present study was focused on the assessment of microstructural anisotropy of IN 625 manufactured by selective laser melting (SLM) and its influence on the material’s room temperature tensile properties. Microstructural anisotropy was assessed based on computational and experimental investigations. Tensile specimens were manufactured using four building orientations (along Z, X, Y-axis, and tilted at 45° in the XZ plane) and three different scanning strategies (90°, 67°, and 45°). The simulation of microstructure development in specimens built along the Z-axis, applying all three scanning strategies, showed that the as-built microstructure is strongly textured and is influenced by the scanning strategy. The 45° scanning strategy induced the highest microstructural texture from all scanning strategies used. The monotonic tensile test results highlighted that the material exhibits significant anisotropic properties, depending on both the specimen orientation and the scanning strategy. Regardless of the scanning strategy used, the lowest mechanical performances of IN 625, in terms of strength values, were recorded for specimens built in the vertical position, as compared with all the other orientations. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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Review

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31 pages, 6742 KiB

Open AccessReview

Self-Lubricating Materials for Extreme Condition Applications

by Merbin John and Pradeep L. Menezes

Materials 2021, 14(19), 5588; https://doi.org/10.3390/ma14195588 - 26 Sep 2021

Cited by 50 | Viewed by 5762

Abstract

Lubrication for extreme conditions, such as high temperature, cryogenic temperature, vacuum pressure, high load, high speed, and corrosive environments, is a continuing challenge among tribologists and space engineers due to the inadequate friction and wear properties of liquid lubricants. As a result, tremendous research effort has been put forward to study lubrication mechanisms for various machine elements under challenging conditions over the past two decades. Self-lubricating materials have been most widely used for adequate lubrication in extreme conditions in recent years. This review paper presents state-of-the-art of materials for lubrication in extreme condition applications in aerospace, automotive, and power generation areas. More specifically, solid lubricants dispersed in various matrices for lubrication application were analyzed in-depth under challenging conditions. This study also reports the self-lubricating materials and their lubrication mechanisms. Finally, various applications and challenges of self-lubricating materials were explored. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings)

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